Modular Electric Vehicle Frame with Lattice Subassemblies
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Solution Overview
Problem
Current electric motor vehicles face challenges in simplifying manufacturing processes, reducing costs, achieving flexibility in production, ensuring sturdiness and safety, and efficiently housing electrical batteries, while also requiring cost-effective and lightweight solutions for small-scale production, especially for city cars and minivans.
Innovation Solution
The vehicle's structural architecture is divided into subassemblies with lattice structures made of high-strength steel, incorporating rotational-moulding technology for bumpers and container bodies, allowing for simplified assembly, high impact energy absorption, and flexible production adaptations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the structural architecture is divided into subassemblies with lattice structures, then manufacturing and assembly are simplified and production flexibility is enhanced, but the structural complexity increases
Solution Approach 1:
The main frame is divided into multiple subassemblies (front subassembly, rear subassembly, lateral subassemblies) that can be manufactured and assembled separately. Each subassembly comprises lattice structures with standardized connection points, enabling modular construction that simplifies manufacturing processes while allowing flexible reconfiguration for different vehicle models
Solution Approach 2:
The lattice structure subassemblies are designed with universal connection interfaces and standardized geometries that can be used across different vehicle types and configurations. The same basic subassembly design can be adapted for city cars, minivans, or cargo vehicles through simple modification of body panels and accessories
2Strength
If high-strength steel lattice structures are used, then sturdiness and impact energy absorption are improved, but production costs increase
Solution Approach 1:
The structure combines high-strength steel lattice work with rotational-moulded plastic components (bumpers, container bodies) to create a composite construction. The steel lattice provides the primary structural strength and impact absorption, while the plastic components provide protective coverage and aesthetic finishing, distributing costs across different material systems with complementary properties
3Weight of moving object
If rotational-moulding technology is used for bumpers and container bodies, then sturdiness and lightness are achieved, but manufacturing complexity increases
Solution Approach 1:
The rotational-moulding process combines multiple functions into single integrated components. Bumpers are molded as unified pieces that incorporate impact-absorbing geometry, mounting provisions, and aesthetic surfaces. Container bodies are molded as complete assemblies with integrated reinforcement ribs, opening mechanisms, and attachment features, eliminating the need for separate fastening hardware and assembly steps
4Productivity
If the main frame is divided into pre-assembled subassemblies, then assembly time is reduced and production flexibility is enhanced, but the number of connection points increases
Solution Approach 1:
Subassemblies are pre-assembled and pre-configured with all necessary connections and attachments before final vehicle assembly. The lattice structures within each subassembly are constructed as complete units with standardized connection interfaces, so that during final assembly only the subassemblies themselves need to be connected, not individual lattice elements
Data Source
Figure 1
Figure 2
Figure 2A
AI summary
An electrically powered motor vehicle comprises a main frame (4), a front axle assembly (6), and a rear axle assembly (7). The main frame (4) includes a front frame subassembly (40), a floor-panel subassembly (41), a rear frame subassembly (42), and a top frame subassembly (43). Each of these frame subassemblies (40-43) comprises a lattice structure including steel box-section elements, preferably high-strength steel elements. Each of the frame subassemblies is prearranged for being preassembled separately and then subsequently assembled together with the other subassemblies so as to constitute the aforesaid main frame (4). The structure is such as to afford high flexibility of production, and presents at the same time considerable safety characteristics, thanks to a high capacity of absorption of impact energy. In one embodiment designed for transport of goods, the motor vehicle is equipped with a transporting body (14) having a hollow-walled body made of plastic material, filled with foamed plastic material, preferably obtained with the rotational-moulding technique.